In poultry farming, every bit of feed counts. When the feed that goes into the mill does not match the feed that comes out, it is time to take a closer look. Shrinkage in feed mills is a silent profit drainer, often going unnoticed until it starts affecting the bottom line.
From the experiences of working closely with feed mill managers and poultry farm owners, one thing is clear. Small steps in tracking process wise weight loss can bring big improvements. Understanding where losses are happening and why they are happening is the key to reducing them. This blog will help you take that first step with simple and practical guidance.
What is Shrinkage and Why Does it Matter
Shrinkage is the difference between the quantity of raw materials received and the amount of finished feed delivered. This can occur at many points in the process and is usually due to moisture loss, spillage, dust, or inaccurate weighing.
Even small losses at each stage add up over time. These hidden gaps can lead to lower productivity, customer dissatisfaction, and reduced profits. By tracking each stage of the feed processing journey, you can begin to see the full picture.
Why You Should Track Process Wise Weight Loss
Most feed mills only record the total feed produced against total input. This gives you the big picture but not the real story. By breaking down the feed production stages and monitoring weight loss at each step, you can pinpoint where things are going wrong.
If losses are high during pelleting, it may be due to excess moisture evaporation. If mixing or grinding stages show inconsistency, it could be from dust leakage or mechanical issues. When you have this clarity, you can fix the root cause instead of guessing.
Key Stages to Watch Closely
Raw Material Receiving
Start from the beginning. Record actual weight when raw materials are delivered. Ensure weighbridges and scales are working accurately. Mismatches here will affect every stage after.
Grinding and Mixing
This is where a lot of dust can escape if systems are not sealed properly. Regular cleaning and well-maintained dust collectors help prevent invisible losses.
Pelleting and Cooling
Feed loses moisture when exposed to heat. While some drying is necessary, too much leads to both weight loss and poor pellet quality. Monitor the temperature and moisture during this stage closely.
Bagging and Storage
Losses can happen during bagging due to poor sealing or spillage. Bags should be filled and sealed properly. Storage areas must maintain correct humidity levels to prevent drying or spoilage.
Final Dispatch
Cross check the final feed weight with the dispatch records. If there is a consistent difference, go back through the process logs to find the gap.
The Importance of Moisture Control
Moisture plays a big role in feed weight. During pelleting and cooling, if the feed dries too much, you lose both weight and nutritional quality. Using moisture meters and maintaining balanced conditioning will help retain weight without harming quality.
Feed that is too dry may also reduce palatability, which can affect bird health and performance. Getting the moisture right means maintaining both profit and poultry performance.
Building a Simple Tracking System
Start by recording weights at every stage. Use a basic sheet to log incoming raw materials, weight after grinding, mixing, pelleting, and bagging. At the end of each batch, compare planned feed against actual feed output.
This method does not need advanced systems to begin with. It just needs consistent practice and teamwork. Over time, these logs become a valuable record that helps you improve efficiency and cut down on waste.
Training Your Team Makes the Difference
Technology and systems matter, but the people running them matter even more. Train your feed mill staff to understand why weight tracking is important. Give them simple goals and responsibility for maintaining records. Encourage them to report any irregularities.
When your team takes ownership, they will start looking out for small issues before they become big losses. This kind of awareness turns into a long term culture of efficiency.
Conclusion
Reducing shrinkage in a poultry feed mill does not start with big changes. It begins with small habits. By tracking weight loss process wise, you gain control over each step of your feed journey. From receiving to dispatch, every stage offers a chance to tighten operations and improve margins.
Start small, track consistently, train your team, and take action based on what the numbers tell you. With time, you will see less waste and more savings in your feed mill operations.
